0310221 JOHNSON PLUG,Adapter

Introduction
This Special Instruction provides the procedure in order to repower a 637D Wheel Scraper. The replacement engine will be a Tier III level C9 engine. See Table 1 for the engine arrangement numbers. The 637D Wheel Scraper was originally equipped with a 3306 engine. The original Wheel Scraper engine is not regulated for emissions. This Special Instruction will provide the information in order to install the Tier III level replacement engine.
Table 1
Engine Arrangement
Original Engine Replacement Engine
7N-1547 Engine Ar
1W-1346 Engine Ar
4N-7671 Engine Ar 417-0641 Engine Ar(1)
20R-1785 Engine Ar(2)
(1) New Repower Engine
(2) Reman Engine - Requires relabel/reflash to software from new repower engine and 275-1165 Oil Pan.This Special Instruction does not include procedures that can be found in your existing manuals. Refer to the original Service Manual, Parts Manual, and Operation and Maintenance Manual for more information.When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.Reference: Service Manual, Parts Manual, Operation and Maintenance Manual.Note: This instruction contains some procedures that come from dealer feedback. If errors are found, submit a feedback in SIS Web or contact the Emissions Retrofit Group.Safety
Personal injury or death can result from sudden machine movement.Sudden movement of the machine can cause injury to persons on or near the machine.To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.
Do not attempt to assemble this machine until you read and you understand the assembly instructions.Improper assembly procedures could result in injury or death.
Personal injury or death can result from improper lifting or blocking.When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Welding on Electronically Controlled Engines
Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
Set the engine control to the "STOP" mode.
Turn OFF the fuel supply to the engine.
Disconnect the negative terminal from the battery.
Disconnect the engine electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor bypass, fuel metering valve and sensors.
Protect the wiring harnesses from welding debris and/or from welding spatter.
Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.
Connect the welder ground cable directly to the engine component that will be welded. Place clamp close as possible to the weld in order to reduce the possibility of current damage engine components.
Use standard welding procedures to weld the materials together.Initial Test
Original Machine Stall Speed
Do not leave the converter in a stall condition for a prolonged period. Only stall the converter to record engine speed and boost pressure. Observe the temperatures of the torque converter oil and cooling system. Do not allow the converter oil or cooling system to overheat.
Record the stall speed for the original machine. Refer to “Techniques for Engine Loading” in Special Instruction, SEHS7050, "Using The 5P2160 Engin